Method and apparatus for applying a stable printed image onto a fabric substrate

ABSTRACT

An ink transfer sheet and method for using the same. The transfer sheet includes a backing layer, a release layer on the backing layer, and an ink receiving layer on the release layer. The ink receiving layer contains a quaternary ammonium salt thereon or impregnated therein. To use the transfer sheet, an ink containing an anionic coloring agent is applied to the ink receiving layer, preferably using thermal inkjet methods. Thereafter, the transfer sheet is positioned on a fabric substrate. Heat is applied to the sheet which causes the release layer and ink receiving layer to adhere to the substrate. The backing layer is then detached from the release layer leaving the release and ink receiving layers (with the printed image thereon) on the substrate. This process transfers the image to the fabric substrate, with the image being stabilized by interactions between the quaternary ammonium salt and anionic coloring agent.

BACKGROUND OF THE INVENTION

[0001] The present invention generally relates to the production ofprinted images on fabric substrates, and more particularly to aspecially-treated ink transfer sheet which is used to thermally deliverink materials to a fabric substrate in a manner which produces a vividand stabilized (e.g. waterfast) printed image.

[0002] In recent years, the popularity of “personalized” printedclothing has greatly increased. For example, a variety of differenttechniques have been developed involving the production ofcustom-printed T-shirts and other clothing items. Of primary importanceis the use of “transfer sheets” which contain monochrome (e.g. singlecolor) or multi-colored printed images that are placed on a clothingitem, followed by the application of heat thereto. As a result, theprinted image on the sheet is “heat transferred” directly to theclothing item or other fabric substrate. This type of process along withrepresentative ink transfer sheets and related procedures is discussedin a variety of references including U.S. Pat. Nos. 4,664,670;4,758,952; 4,767,420; 4,980,224; 4,966,815; 5,139,917; and 5,236,801.

[0003] The basic ink transfer sheets of primary concern in the presentcase are commercially-available products which can be obtained from, forexample, Foto-Wear, Inc. of Milford, Pa. (USA). These sheets normallyinvolve three main layers, namely, (1) an inert backing layer which isultimately removed and discarded; (2) a detachable release layerpositioned on the backing layer which is designed for easy removal fromthe backing layer during the thermal transfer process; and (3) an inkreceiving (e.g. ink absorbent) layer positioned on the release layer. Inuse, a printed image is initially applied to the ink receiving layer asdiscussed in greater detail below. Thereafter, the ink transfer sheetcontaining the printed image is positioned on a desired fabric substrate(e.g. a T-shirt or other clothing item) with the ink receiving layer(and printed image thereon) directly contacting the substrate. Heat isthen applied by a conventional heated platen apparatus known in the artfor thermal transfer purposes or a standard household iron in an amountsufficient to cause the release layer and accompanying ink receivinglayer (containing the printed image) to adhere to the substrate. Becausethe release layer is typically produced from a low melting pointpolymeric composition, it softens substantially during the heatingprocess which not only facilitates adhesion to the fabric substrate butalso enables rapid detachment of the release layer from the backinglayer. During or immediately after the application of heat to the inktransfer sheet on the fabric substrate, the backing layer is physicallyremoved (e.g. peeled away) from the remaining layers of the transfersheet. As a result, the release layer and attached ink receiving layercontaining the printed image remain on the fabric substrate. In thismanner, the printed image is effectively transferred to the substrate togenerate a printed final product. It is important to note that theprinted image (which is usually applied to the ink transfer sheet in a“reverse” configuration so that it will be properly oriented on thefabric substrate) is readily visible on the substrate since the releaselayer and ink receiving layer are substantially colorless (e.g.transparent). As a result, the printed image can be seen through theselayers.

[0004] Heat-based ink transfer systems of the type described above haverecently become available to consumers for in-home use. Consumers arenow able to apply computer-generated or other images directly to aselected ink transfer sheet using commercially-available printingdevices of conventional design. However, whether the printing process isbeing undertaken by consumers or on a large-scale commercial level, itis important that the printed image be stable or “waterfast” after it isapplied to a selected fabric substrate. The term “waterfast” as usedherein shall signify a printed image which does not smear, bleed, run,fade, or the like when exposed to moisture (e.g. water and/orwater-based materials). If the printed image on the fabric substrate(e.g. T-shirt) is not sufficiently waterfast, it will progressively fadeafter repeated machine washings, thereby resulting in a product with adull and indistinct character.

[0005] Prior to development of the present invention, a need existed foran effective thermal transfer process in which the resulting printedimages remained clear, stable (e.g. waterfast), and fade-resistant overtime. The present invention satisfies this goal through the use of aunique modified ink transfer sheet which includes chemical compositionsthat are capable of binding to charged coloring agents (e.g. dyemolecules) in order to produce stabilized images. Likewise, the claimedinvention is especially suitable for use in connection with thermalinkjet printing systems which enable the entire printing process to beaccomplished by consumers at home. The claimed process and transfersheets therefore represent an advance in the art of thermal transferprinting as discussed in greater detail below.

SUMMARY OF THE INVENTION

[0006] It is an object of the present invention to provide an improvedink transfer sheet and process for applying printed images to fabricsubstrates.

[0007] It is another object of the invention to provide an improved inktransfer sheet and process for applying printed images to fabricsubstrates which is suitable for use with many different printingsystems.

[0008] It is another object of the invention to provide an improved inktransfer sheet and process for applying printed images to fabricsubstrates which is especially appropriate for use with inkjet printingsystems (e.g. thermal inkjet units and other comparable systems).

[0009] It is another object of the invention to provide an improved inktransfer sheet and process for applying printed images to fabricsubstrates which uses a minimal number of process steps and materials totransfer the desired images.

[0010] It is a further object of the invention to provide an improvedink transfer sheet and process for applying printed images to fabricsubstrates in which the printed images are highly stable (e.g.waterfast) and fade resistant after repeated machine washings.

[0011] It is a further object of the invention to provide an improvedink transfer sheet and process for applying printed images to fabricsubstrates in which the printed images remain vivid and crisp afterrepeated machine washings.

[0012] It is a still further object of the invention to provide animproved ink transfer sheet and process for applying printed images tofabric substrates which is suitable for use in connection with a widevariety of different ink compositions and fabric substrates.

[0013] It is an even further object of the invention to provide animproved ink transfer sheet and process for applying printed images tofabric substrates which is readily applicable to both monochrome (e.g.single color) and multi-color printed images.

[0014] It is an even further object of the invention to provide animproved ink transfer sheet and process for applying printed images tofabric substrates which generally involves a minimal level of complexityand is suitable for use by both commercial users and consumers on anin-home basis.

[0015] In accordance with the present invention, a highly efficientmethod for applying clear, vivid, and stable printed images onto fabricsubstrate materials (e.g. T-shirts and other clothing items) isdisclosed. The claimed ink transfer sheet and printing method enable theproduction of printed images using readily-available ink materials, withthe resulting images being highly stable (e.g. waterfast) andfade-resistant even after multiple machine washing cycles. A briefsummary of the present invention (e.g. the claimed ink transfer sheetand thermal transfer process) will now be provided, with a more in-depthdiscussion of these items being presented in the following DetailedDescription of Preferred Embodiments section.

[0016] In accordance with the claimed invention, a unique ink transfersheet and process for using the same are disclosed. To achieve the goalsof the invention as discussed above, a specialized ink transfer sheetstructure is initially provided. The transfer sheet is of multi-layerconstruction and includes a backing layer, a detachable release layerpositioned on top of and adhered to the backing layer, and an inkreceiving layer. The backing layer is primarily designed to providesupport for the other layers in the transfer sheet while the releaselayer is used to adhere the ink receiving layer and printed image ontothe fabric substrate. The ink receiving layer is specifically formulatedto allow the adhesion and/or absorption of ink materials thereon so thata defined printed image can be effectively transferred. Furtherinformation regarding the various components and materials which can beused in connection with the multiple layers of the ink transfer sheetwill be presented below.

[0017] In accordance with the claimed invention which represents adeparture from the use of conventional transfer sheet structures, theink receiving layer includes an additional ingredient which isspecifically designed to produce an image-stabilizing effect and controlwaterfastness problems (e.g. fading) as previously discussed.Specifically, the ink receiving layer further includes at least onequaternary ammonium salt. The term “quaternary ammonium salt” as usedherein shall be defined to involve a material which includes fourseparate groups (not necessarily the same) that are bonded to nitrogenin order to produce a positively-charged quaternary ammonium ion (acation). At least one of these groups will be organic in character (e.g.will contain one or more carbon atoms). The positive charge of thiscation is balanced by a selected anion. A quaternary ammonium saltproduced in accordance with this general definition will have thefollowing basic structural formula:

[0018] In this formula, R₁, R₂, R₃, and R₄ may be selected from a widevariety of organic groups including but not limited to aliphatic and/oraromatic groups which are substituted, non-substituted, branched, ornon-branched as will be discussed in greater detail below. Likewise, inaccordance with the definition provided above, R₁, R₂, R₃, and/or R₄ canconsist of a hydrogen group (H), provided that at least one of R₁, R₂,R₃, and/or R₄ is organic (carbon-containing) in character. In addition,X will consist of an anion (counterion) selected from a wide variety ofanions which will likewise be described further below. Effectivesolutions containing quaternary ammonium salts which may be used toproduce the claimed ink transfer sheet by direct application theretowill have a quaternary ammonium salt concentration level of about0.5-15% by weight. While the present invention shall not be exclusivelylimited to any particular quaternary ammonium salt compositions,representative and preferred quaternary ammonium salt compounds suitablefor use in the claimed ink transfer sheet include but are not limited totricaprylyl methyl ammonium chloride, ditallow dimethyl ammoniumchloride, tetraoctyl ammonium bromide, and tridodecyl ammonium chloride.

[0019] To produce the completed ink transfer sheet, an untreatedtransfer sheet structure is first provided which includes all of thelayers listed above, namely, (1) the backing layer; (2) the releaselayer positioned on the backing layer; and (3) the ink receiving layeron the release layer. This basic structure is a commercially availableproduct as discussed above. However, to manufacture the claimed inktransfer sheet (e.g. the treated sheet), the selected quaternaryammonium salt is delivered (preferably in the form of an aqueoussolution) directly to the upper surface of the ink receiving layer ofthe sheet. Application of the quaternary ammonium salt may beaccomplished in any conventional manner including the use of knownspraying devices or other coating systems. In accordance with thepresent invention, the selected quaternary ammonium salt may ultimatelyreside directly on top of the ink receiving layer or instead may beentirely or partially impregnated (absorbed) within the ink receivinglayer. Both of these variations shall be considered equivalent to eachother in form and function. The extent to which the quaternary ammoniumsalt will penetrate the ink receiving layer will depend on a variety offactors including the type and porosity of the materials used tomanufacture the ink receiving layer as determined by preliminary pilottesting. While the claimed invention shall not be strictly limited toany particular amount of quaternary ammonium salt on the ink transfersheet, a sufficient amount of quaternary ammonium salt will be employedin a preferred embodiment to achieve an average dry salt concentrationof about 2-10 g of quaternary ammonium salt per square meter (m²) of thefinished (treated) ink transfer sheet.

[0020] After production of the treated ink transfer sheet, the sheet maybe used to transfer a desired printed image (either monochrome[single-color] or multi-colored) onto a selected fabric substrate (e.g.a T-shirt) in a stable, crisp, and waterfast manner. To achieve thisgoal, a prepared ink transfer sheet of the type described above isinitially provided which again includes at least one quaternary ammoniumsalt as an active ingredient. Thereafter, an ink composition is alsoprovided which contains at least one anionic (e.g. negatively-charged)coloring agent and an ink vehicle. The present invention shall not berestricted to any particular coloring agents and ink vehicles, with awide variety of different chemical compositions being suitable for thesepurposes as specifically discussed in the following Detailed Descriptionof Preferred Embodiments section. However, for the purposes of thisinvention, the term “anionic coloring agent” shall be defined toencompass selected dye compositions having at least one functionalchemical group which is negatively-charged and capable of reacting withthe positively-charged quaternary ammonium salt in solution to produce a“complex” from the selected coloring agent. Exemplary dye/coloring agentcompositions suitable for this purpose will generally include but not belimited to carboxylated and/or sulfonated dye materials known in theart, with specific examples again being provided below. Furthermore, theterm “coloring agent” may also encompass colorant/pigment dispersionsknown in the art which are made using dispersants that also include atleast one functional chemical group which is capable of reacting withquaternary ammonium ions in solution to yield a complex. In a preferredembodiment, dispersants may be used which are carboxylated, sulfonated,or the like. Specific examples of color pigment dispersions which may beemployed in the claimed process will be presented below.

[0021] After the desired ink composition containing at least one anioniccoloring agent has been selected, it is thereafter delivered onto theink receiving layer of the ink transfer sheet in order to form a printedimage on the transfer sheet. Many different techniques may be used toaccomplish ink delivery, although thermal inkjet printing methods arepreferred and provide optimum results (e.g. a maximum level of clarity,simplicity, and high resolution). While thermal inkjet printing methodsare of primarily interest, other inkjet systems may also be used todeliver the ink compositions of concern including piezoelectric inkjetprinters, “continuous” inkjet devices, and the like. To accomplish inkdelivery using thermal inkjet printing techniques, a thermal inkjetprinting apparatus (printer unit) is initially provided which comprisesat least one ink cartridge unit therein. The ink cartridge includes ahousing and a printhead affixed to or within the housing. The printheadcontains ink expulsion means for delivering ink materials from the inkcartridge, with typical ink expulsion means consisting of a plurality ofthin-film resistor elements which, when electrified, heat the ink andselectively expel it from the cartridge as discussed further below. Thehousing of the ink cartridge further includes a supply of an inkcomposition therein which contains an ink vehicle and at least oneanionic coloring agent as defined above. The supply of the inkcomposition is in fluid communication with the ink expulsion meansassociated with the printhead so that the printhead can selectivelydeliver the ink on-demand.

[0022] Delivery of the ink composition onto the ink receiving layer ofthe claimed ink transfer sheet is specifically accomplished in a thermalinkjet system by placing the ink transfer sheet directly within thethermal inkjet printing apparatus/printer. Thereafter, the ink expulsionmeans of the printhead associated with the ink cartridge is activated(e.g. energized) in order to deliver the ink composition from the inkcartridge onto the ink receiving layer of the transfer sheet to therebyform a clear and defined monochrome or multi-colored printed image onthe sheet. However, as indicated above, the claimed invention shall notbe exclusively limited to the use of thermal inkjet printing techniques,with other printing methods also being applicable.

[0023] Regardless of which ink delivery method is selected, once the inkcomposition is delivered to the ink receiving layer of the transfersheet in a desired pattern, the anionic (e.g. negatively-charged)coloring agent in the ink composition will bind to thepositively-charged quaternary ammonium salt in order to produce achemical “complex” which is effectively fixed to the ink transfer sheet.This fixation process ultimately results in enhanced image stability onthe fabric substrate which is characterized by improved waterfastnessand reduced fading even after repeated machine washings.

[0024] Once the printed image has been applied to the ink receivinglayer on the ink transfer sheet, the transfer sheet is placed on andagainst the selected fabric substrate so that the ink receiving layer(and the printed image) is in physical contact with the substrate. Manyfabric materials may be used for this purpose including cotton, cottonblends, and synthetic compositions, with the present invention not beinglimited to any particular textile products for this purpose.Representative fabric materials which are particularly suitable for usein the claimed process will be discussed below. Thereafter, heat isapplied to the ink transfer sheet while the transfer sheet is in directcontact with (positioned on) the fabric substrate. Heat isconventionally applied to the ink transfer sheet (e.g. using a standardheated platen apparatus or household iron) in an amount sufficient tocause the release layer and ink receiving layer associated therewith tosoften and adhere to the fabric substrate. This is readily accomplishedin accordance with the low melting point characteristics of thepolymeric compounds which are typically used to manufacture the releaselayer. While the invention shall not be restricted to any particulartemperature levels and processing times at this stage of the claimedmethod (which are typically determined by preliminary pilot studies),heating of the ink transfer sheet will preferably involve temperaturelevels of about 150-200° C. applied for approximately 0.3-3.0 minuteswhile the ink transfer sheet is in direct contact with the fabricsubstrate. Likewise, to ensure complete transfer of the printed image tothe fabric substrate, it is preferred that pressure be applied to thetransfer sheet positioned on the substrate during the application ofheat in an amount sufficient to facilitate complete contact between thetransfer sheet and the substrate. In a representative embodiment, thispressure would typically involve about 0.05-2.0 lbs/in² of the transfersheet, although the exact pressure level to be used in a given situationmay be determined in accordance with preliminary routine testing.

[0025] After or during the application of heat as discussed above, thebacking layer is removed (e.g. by physical detachment or “peeling”) fromthe ink transfer sheet in order to separate the release layer from thebacking layer. As a result, the release layer and attached ink receivinglayer (with the printed image thereon) are left on the fabric substrate.In this manner, the printed image is directly transferred to thesubstrate. It is important to note that the printed image (which isusually applied in a “reverse” configuration to the ink transfer sheetso that it will be properly oriented on the fabric substrate) is readilyvisible on the fabric substrate since both the release layer and inkreceiving layer are substantially colorless (e.g. transparent). Aspreviously indicated, the anionic (e.g. negatively-charged) coloringagent and the positively-charged quaternary ammonium salt interact toproduce a precipitation/complexation reaction which stabilizes theprinted image on both the ink transfer sheet and the fabric substrate.The printed image is vivid, crisp, and characterized by a high level ofwaterfastness (compared with ink transfer sheets that do not employquaternary ammonium salts). As a result, the stabilized image avoidsfading, color bleed, and a loss of image resolution even after repeatedmachine washings.

[0026] The present invention represents an advance in the art of thermaltransfer printing on fabric substrates which provides numerous benefitsand advantages including: (1) the rapid printing of clear, vivid, anddistinct images with a minimal amount of equipment and process steps;(2) enhanced image waterfastness and fade-resistance; (3) a minimallevel of complexity and required equipment which facilitates at-home useby consumers; (4) the ability to use thermal inkjet technology (or otherinkjet systems) to generate high-resolution multi-color images which arecharacterized by improved stability levels; and (5) the ability toaccomplish these goals using low-cost materials and equipment. These andother objects, features, and advantages of the invention will bediscussed below in the following Brief Description of the Drawings andDetailed Description of Preferred Embodiments section.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027]FIG. 1 is a schematic illustration of a representative thermalinkjet cartridge unit which is suitable for use in the process of thepresent invention.

[0028]FIG. 2 is a cross-sectional schematic view of a representativemulti-layer ink transfer sheet suitable for use in the claimed process,with the layers shown therein being enlarged for the sake of clarity.

[0029]FIG. 3 is a cross-sectional schematic view of an alternativemulti-layer ink transfer sheet suitable for use in the claimed process,with the layers shown therein being enlarged for the sake of clarity.

[0030]FIG. 4 is a sequential, schematic view of the steps which are usedto transfer a printed image onto a fabric substrate using the materialsand processes of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0031] As indicated above, the present invention involves a unique andhighly effective ink transfer sheet and method which enable the deliveryof stable printed images to fabric substrates. The resulting images areeffectively stabilized on the substrate and are characterized by a highlevel of waterfastness and a vivid appearance. In particular, theprinted images are fade-resistant even after repeated machine washingcycles. These and other benefits of the present invention areaccomplished through the use of a treated ink transfer sheet andspecially-selected ink compositions (e.g. dyes/pigments) which interactto enhance image stability. It is likewise an important feature of theclaimed invention that the initial printing of the image on the inktransfer sheet can be accomplished using thermal inkjet technology. Thisfeature enables the entire thermal transfer process to be readilyundertaken by consumers using conventional personal computer systems andprinting equipment. However, while the present invention will bediscussed herein with reference to inkjet technology (e.g. thermalinkjet systems), it shall not be limited to any particular printingsystem for image generation. Likewise, the claimed process and productshall not be exclusively restricted to any of the numerical parametersset forth below which represent preferred embodiments and are providedfor example purposes.

A. Thermal Inkjet Technology

[0032] Before discussing the specialized ink transfer sheet and processof the claimed invention, a brief review of thermal inkjet technologyand its applicability to the present case is in order. Thermal inkjetprinting systems basically involve the use of an ink cartridge whichincludes at least one ink reservoir chamber in fluid communication witha substrate having a plurality of resistors thereon. Selectiveactivation of the resistors causes thermal excitation of the ink andexpulsion thereof from the ink cartridge. As noted above, representativethermal inkjet systems are discussed in U.S. Pat. No. 4,500,895 to Bucket al.; U.S Pat. No. 4,794,409 to Cowger et al.; U.S. Pat. No. 4,509,062to Low et al.; U.S. Pat. No. 4,929,969 to Morris; U.S. Pat. No.4,771,295 to Baker et al.; and the Hewlett-Packard Journal, Vol. 39, No.4 (August 1988).

[0033] In accordance with a preferred method for producing a printedimage on the ink transfer sheet of the present invention (discussedbelow), a representative thermal inkjet cartridge 10 is schematicallyillustrated in FIG. 1. With reference to FIG. 1, the cartridge 10consists of a housing 12 preferably of unitary (e.g. single-piece)construction and manufactured from plastic. The housing 12 furtherincludes a top wall 16, a bottom wall 18, a first side wall 20, and asecond side wall 22. In the embodiment of FIG. 1, the top wall 16 andthe bottom wall 18 are substantially parallel to each other and of thesame size. Likewise, the first side wall 20 and the second side wall 22are substantially parallel to each other and of the same size.

[0034] With continued reference to FIG. 1, the housing 12 furtherincludes a front wall 32. Surrounded by the front wall 32, top wall 16,bottom wall 18, first side wall 20, and second side wall 22 is aninterior ink-retaining chamber or compartment 33 within the housing 12.The front wall 32 further includes an externally-positioned supportstructure 34 which is constructed of a plurality of outwardly-extendingside sections 36, 40, 42, 44 with a substantially rectangular centerzone 50 therebetween. Positioned within the center zone 50 and passingentirely through the front wall 32 of the housing 12 is an elongate inkoutlet port 52 which communicates with the chamber 33 inside the housing12.

[0035] Fixedly secured to the front wall 32 of the housing 12 (e.g.preferably using an adhesive composition known in the art) andpositioned within the center zone 50 of the support structure 34 is asubstrate in the form of a plate member 56 having a plurality of thinfilm resistors 58 thereon which are schematically illustrated andenlarged for the sake of clarity in FIG. 1 Likewise, the plate member 56further includes at least one opening 60 therethrough whichsubstantially registers and communicates with the ink outlet port 52 inthe assembled cartridge 10. In addition, secured to the plate member 56by adhesive, welding, or the like is an outer plate conventionally knownas an “orifice plate” 62. The orifice plate 62 is preferably made of aninert metal composition (e.g. gold-plated nickel), and further includesat least one ink ejection orifice 66 therethrough. The ink ejectionorifice 66 is arranged on the orifice plate 62 so that it substantiallyregisters with the opening 60 through the plate member 56 in theassembled cartridge 10. For the purposes of this invention, plate member56, thin film resistors 58, opening 60, orifice plate 62, and inkejection orifice 66 shall collectively be characterized as “inkexpulsion means” 68, the operation of which will be described below.Furthermore, as shown in FIG. 1, the ink expulsion means 68 incombination with the support structure 34 (e.g. including side sections36, 40, 42, 44, center zone 50, and ink outlet port 52) shallcollectively be characterized as the printhead 70 of the ink cartridge10 which is fixedly secured to the cartridge 10.

[0036] As noted above, the claimed invention shall not be limitedexclusively to the cartridge 10 shown in FIG. 1 or to thermal inkjetcartridges in general. For example, other cartridges/ink deliverysystems may be encompassed within the present invention which involveprinthead units having different ink expulsion means other than the thinfilm resistor assembly set forth above. Alternative ink expulsion meansencompassed within the present invention shall include but not belimited to piezoelectric ink drop expulsion systems of the general typedisclosed in U.S. Pat. No. 4,329,698 to Smith, dot matrix systems of thetype disclosed in U.S. Pat. No. 4,749,291 to Kobayashi et al., as wellas other comparable systems which are primarily concerned with thedelivery of water-containing ink compositions.

[0037] With continued reference to FIG. 1, the ink cartridge 10 furtherincludes an ink filter 74 which is mounted within the chamber 33 of thehousing 12 as illustrated. Specifically, the ink filter 74 is mounteddirectly adjacent to and against the ink outlet port 52 in the frontwall 32 of the housing 12. The ink filter 74 is preferably manufacturedfrom stainless conventionally known as an “orifice plate” 62. Theorifice plate 62 is preferably made of an inert metal composition (e.g.gold-plated nickel), and further includes at least one ink ejectionorifice 66 therethrough. The ink ejection orifice 66 is arranged on theorifice plate 62 sothat it substantially registers with the opening 60through the plate member 56 in the assembled cartridge 10. For thepurposes of this invention, plate member 56, thin film resistors 58,opening 60, orifice plate 62, and ink ejection orifice 66 shallcollectively be characterized as “ink expulsion means” 68, the operationof which will be described below. Furthermore, as shown in FIG. 1, theink expulsion means 68 in combination with the support structure 34(e.g. including side sections 36, 40, 42, 44, center zone 50, and inkeoutlet port 52) shall collectively be characterized as the printhead 70of the ink cartridge 10 which is fixedly secured to the cartridge 10.

[0038] As noted above, the claimed invention shall not be limitedexclusively to the cartridge 10 shown in FIG. 1 or to thermal inkjetcartridges in general. For exampl, other cartridges/ink delivery systemsmay be encompassed within the present invention which involve printheadunits having different ink expulsion means other than the thin filmresistor assembly set forth above. Alternative ink expulsion meansencompassed within the preseent invention shall include but not belimited to piezoelectric ink drop expulsion systems of the general typedisclosed in U.S. Pat. No. 4,329,698 to Smith, dot matrix systems of thetype disclosed in U.S. Pat. No. 4,749,291 to Kobayashi et al., as wellas other comparable systems which are primarily concerned with thedelivery of water-containing ink compositions.

[0039] With continued reference to FIG. 1, the ink cartridge 10 furtherincludes an ink filter 74 which is mounted within the chamber 33 of thehousing 12 as illustrated. Specifically, the ink filter 74 is mounteddirectly adjacent to and against the inke outlet port 52 in the frontwall 32 of the housing 12. The ink filter 74 is preferably manufacturedfrom stainless steel wire mesh.

[0040] As schematically illustrated in FIG. 1, the ink cartridge 10 alsoincludes a cap member 80 which is adapted for affixation (e.g. using aconventional adhesive) to the open rear portion 82 of the housing 12.The cap member 80 likewise includes at least one air vent 84 which maybe covered with a porous plastic membrane (not shown) as discussed inU.S. Pat. No. 4,771,295 to Baker et al. which allows air to passtherethrough while preventing ink leakage from the cartridge 10.

[0041] To deliver an ink composition to a selected substrate (e.g. madeof fabric in this case) using the cartridge 10, the ink-retainingchamber 33 of the cartridge 10 is supplied with the claimed inkcomposition (schematically designated at reference number 100 in FIG. 1)which includes at least one anionic coloring agent, an ink vehicle, anda number of other ingredients, with all of these components beingdiscussed in detail below. Thereafter, the ink cartridge is activated inorder to apply the ink composition 100 from the chamber 33 to a selectedsubstrate (which, in this case, involves an ink transfer sheet 200). Theterm “activation” as used herein basically involves a process in whichthe ink expulsion means 68 is directed by the printer unit (not shown inFIG. 1) to deliver ink from the chamber 33 to the selected substrate(e.g. ink transfer sheet). This is accomplished by selectivelyenergizing the thin film resistors 58 on the plate member 56 (FIG. 1).As a result, ink positioned at the opening 60 in the plate member 56 isthermally excited and expelled outwardly through the ink ejectionorifice 66 in the orifice plate 62 onto the substrate. In this manner,the cartridge 10 may be used to generate a printed image on thesubstrate. Further information concerning the thermal inkjet printingprocess is again set forth in the Hewlett-Packard Journal, Vol. 39, No.4 (August 1988).

[0042] While the representative ink cartridge 10 illustrated in FIG. 1is basically configured to produce monochromatic (e.g. single colorimages), multi-color ink cartridge units may likewise be employed.Accordingly, the present invention shall not be exclusively limited toany particular type of thermal inkjet delivery system, with manydifferent systems being suitable for use. For example, representativecommercially-available ink cartridge units which may be employed inconnection with the claimed process can be obtained from theHewlett-Packard Company of Palo Alto, Calif. (USA) under the followingproduct designations/numbers: 51641A, 51645A, 51640C, 51640A, 51629A,and 51649A.

B. The Ink Composition to be Employed

[0043] Many different ink materials may be used in producing printedimages on the ink transfer sheet and fabric substrate in accordance withthe present invention. In this regard, the invention shall not berestricted to the generation of images using any particular ink product.However, at a minimum, the selected ink composition will include an inkvehicle and at least one coloring agent, with the term “coloring agent”being defined to encompass a wide variety of different dye materials andcolors including black. Regarding the particular coloring agent to beemployed, a preferred composition for this purpose will consist of ananionic coloring agent. The term “anionic coloring agent” involves achemical coloring composition which is defined to include one or morenegatively-charged groups. For example, representative and preferrednegatively-charged functional groups typically associated with theanionic coloring agents of the present invention include but are notlimited to —COO⁻, —SO₃ ⁻, —CH₂COO⁻, CH₂CH₂COO⁻, and others. Exemplaryanionic materials suitable for use in the ink composition are listed inU.S. Pat. No. 4,963,189 to Hindagolla. Such materials are black andinvolve the following basic structure:

[0044] [W=—COOH X=—H or —COOH Y=—H, —COOH, or —SO₃H Z=—H, —COOH, or—SO₃H R=—H, —CH₂COOH, or —CH₂CH₂COOH]

[0045] Specific and exemplary dye structures are provided in Table Ibelow: TABLE I Dye # X W Y Z R 1 3-COOH 5-COOH H H H 2 3-COOH 5-COOHCOOH H H 3 3-COOH 5-COOH H COOH H 4 3-COOH 5-COOH H SO₃H H 5 3-COOH5-COOH SO₃H H H 6 H 4-COOH H COOH H 7 3-COOH 4-COOH H H CH₂COOH 8 2-COOH5-COOH H SO₃H CH₂COOH 9 3-COOH 5-COOH SO₃H H CH₂COOH 10 3-COOH 5-COOH HH CH₂CH₂COOH 11 3-COOH 5-COOH H COON CH₂COOH

[0046] Additional dye materials suitable for use in the invention as theanionic coloring agent are described in the Color Index, Vol. 4, 3rded., published by The Society of Dyers and Colourists, Yorkshire,England (1971), which is a standard text that is well known in the art.Exemplary dye materials listed in the Color Index, supra, which areappropriate for use herein include but are not limited to the followingcompositions: C.I. Direct Yellow 11, C.I. Direct Yellow 86, C.I. DirectYellow 132, C.I. Direct Yellow 142, C.I. Direct Red 9, C.I. Direct Red24, C.I. Direct Red 227, C.I. Direct Red 239, C.I. Direct Blue 9, C.I.Direct Blue 86, C.I. Direct Blue 189, C.I. Direct Blue 199, C.I. DirectBlack 19, C.I. Direct Black 22, C.I. Direct Black 51, C.I. Direct Black163, C.I. Direct Black 169, C.I. Acid Yellow 3, C.I. Acid Yellow 17,C.I. Acid Yellow 23, C.I. Acid Yellow 73, C.I. Acid Red 18, C.I. AcidRed 33, C.I. Acid Red 52, C.I. Acid Red 289, C.I. Acid Blue 9, C.I. AcidBlue 61:1, C.I. Acid Blue 72, C.I. Acid Black 1, C.I. Acid Black 2, C.I.Acid Black 194, C.I. Reactive Yellow 58, C.I. Reactive Yellow 162, C.I.Reactive Yellow 163, C.I. Reactive Red 21, C.I. Reactive Red 159, C.I.Reactive Red 180, C.I. Reactive Blue 79, C.I. Reactive Blue 216, C.I.Reactive Blue 227, C.I. Reactive Black 5, C.I. Reactive Black 31, andmixtures thereof. These materials are known in the art and commerciallyavailable from a variety of sources. Representative sources for dyematerials of the type described above which may be used in the presentinvention include but are not limited to the Sandoz Corporation of EastHanover, N.J. (USA), Ciba-Geigy of Ardsley, N.Y. (USA) and others.

[0047] It should also be noted that the term “coloring agent” as usedherein shall further encompass pigment dispersion materials known in theart which basically involve a water insoluble colorant (e.g. a pigment)which is rendered soluble through association with a dispersant (e.g. anacrylic dispersant).

[0048] Specific pigments which may be employed to produce pigmentdispersion materials are known in the art, and the present inventionshall not be restricted to any particular chemical compositions in thisregard. Examples of such pigments include carbon black and the followingcompositions which are listed in the Color Index, supra: C.I. PigmentBlack 7, C.I. Pigment Blue 15, C.I. Pigment Red 2, C.I. Pigment Red 122,C.I. Pigment Yellow 17, and C.I. Disperse Red 17. As noted above,dispersant materials suitable for combination with the foregoingpigments will include acrylic monomers and polymers known in the art. Anexemplary commercial dispersant involves a product sold by W.R. Graceand Co. of Lexington, Mass. (USA) under the trademark DAXAD 30-30.However, as previously indicated, the claimed invention shall not belimited to the dyes and/or pigment dispersion materials listed above.Other chemically comparable materials may be employed which aredetermined by reasonable investigation to be suitable for the purposesset forth herein. In a preferred embodiment, the ink composition of theinvention will include about 2-7% by weight total anionic coloring agenttherein (e.g. whether a single coloring agent or combined coloringagents are used).

[0049] The ink composition will also include an ink “vehicle” which isessentially used as a carrier medium for the other components in thecompleted ink product. Many different materials may be employed as theink vehicle, with the present invention not being limited to anyparticular compositions for this purpose. A preferred ink vehicle willconsist of water, although other supplemental compositions incombination with water including 2-pyrrolidone, ethoxylated glycerol,diethylene glycol, 1,5-pentanediol, N-methyl pyrrolidone, 2-propanol,and 2-ethyl-2-hydroxymethyl-1,3-propanediol may be employed. All ofthese materials can be used in various combinations as determined bypreliminary pilot studies involving the ink compositions of concern.However, in a preferred embodiment, the ink composition will includeabout 70-80% by weight total combined ink vehicle, wherein at leastabout 30% by weight or more of the total ink vehicle will involve water(with the balance consisting of any one of the above-listed supplementalcompositions).

[0050] Next, the ink composition may include a number of optionalingredients in varying amounts. For example, an optional biocide may beadded to prevent any microbial growth in the final ink product.Exemplary biocides suitable for this purpose would include proprietaryproducts sold under the trademarks PROXEL GXL by Imperial ChemicalIndustries of Manchester, England; UCARCID 250 by Union Carbide ofDanbury, Conn. (USA); and NUOSEPT 95 by Huls America, Inc. ofPiscataway, N.J. (USA). In a preferred embodiment, if a biocide is used,the final ink composition will include about 0.05-0.5 k by weightbiocide, with about 0.30 k by weight being preferred.

[0051] Another optional ingredient to be added to the ink compositionwill involve one or more buffering agents. The use of a selectedbuffering agent or multiple (combined) buffering agents is designed tostabilize the pH of the ink composition. In a preferred embodiment, thedesired pH of the ink composition will range from about 4-9. Exemplarybuffering agents suitable for this purpose will comprise sodium borate,boric acid, and phosphate buffering materials known in the art for pHcontrol. The selection of any particular buffering agents and the amountof buffering agents to be used (as well the decision to use bufferingagents in general) will be determined in accordance with preliminarypilot studies on the particular ink compositions of concern.

[0052] A still further optional ingredient which may be employed in theink composition is an auxiliary bleed control agent. This material isespecially appropriate for multi-color printing systems. Exemplary bleedcontrol agents suitable for this purpose will involve magnesium nitrate,calcium nitrate, or mixtures of both. In a preferred embodiment, the inkcomposition will include about 3-6% by weight total auxiliary bleedcontrol agent therein (if used). However, the selection of any givenbleed control agent, the exact amount of bleed control agent to beadded, and the general need for a bleed control agent may be determinedin accordance with preliminary investigations involving the othercomponents chosen for use in the ink composition. Additional ingredients(e.g. surfactants) may also be included in the ink composition ifneeded.

C. The Ink Transfer Sheet

[0053] In accordance with the invention, a specialized ink transfersheet is provided which is designed to improve the overall stability(e.g. waterfastness) of printed images transferred to fabric substrates.While the claimed product and process shall not be exclusivelyrestricted to any particular ink transfer sheet, a representative andpreferred structure will consist of three basic layers as illustratedcross-sectionally and in an enlarged, schematic format in.FIG. 2. Thebasic ink transfer sheet described below and illustrated in FIG. 2 (e.g.the 3-layer sheet structure excluding the unique additive discussedherein) is conventional in design and commercially available from, forexample, Foto-Wear, Inc. of Milford, Pa. (USA). Likewise, ink transfersheets of the same general type discussed above in connection with theink transfer sheet 200 shown in FIG. 2 are generally described in U.S.Pat. Nos. 4,980,224 and 4,966,815. With reference to FIG. 2, a transfersheet 200 is provided which first includes a backing layer 202. Thebacking layer 202 will typically have an average thickness of about0.05-0.15 mm and may be produced from a wide variety of materials havinga high degree of tear resistance and overall strength. Even though theclaimed invention shall not be limited to any particular compositions inconnection with the backing layer 202, representative materials suitablefor this purpose include paper, polyester, cellophane, nylon, andvarious other plastic materials known in the art for this purpose (e.g.as discussed in U.S. Pat. No. 4,732,815).

[0054] Temporarily adhered to the upper surface 204 of the backing layer202 is an intermediate or release layer 206 which entirely covers thebacking layer 202. The release layer 206 will typically have an averagethickness of about 0.01-0.06 mm and may likewise be produced from a widevariety of materials. However, low melting point polymeric compositionswhich typically melt at temperatures of about 100-180° C. or less arepreferred in order to facilitate detachment of the release layer 206from the backing layer 202 during the heat transfer process and tolikewise enable proper adhesion of the release layer 206 to the selectedfabric substrate. In this regard, representative materials suitable forproducing the release layer 206 include but are not limited topolyethylene, polyester compositions, polyamides, and other similarpolymers known in the art for this purpose as discussed in U.S. Pat. No.4,294,641.

[0055] Finally, in the ink transfer sheet 200 shown in FIG. 2, an inkreceiving layer 212 is provided on the upper surface 210 of the releaselayer 206. The ink receiving layer 212 is designed to receive and retain(e.g. absorb) ink compositions which are delivered to the ink transfersheet 200 using the selected ink delivery system. In this regard, theink receiving layer 212 should have sufficient ink absorptivecapabilities to ensure proper adhesion of the ink to the ink transfersheet 200, and to facilitate sufficient ink absorption on the sheet 200so that a high level of print quality is maintained. In the preferredink transfer sheet 200 shown in FIG. 2, the ink receiving layer 212 willhave an average thickness of about 0.01-0.03 mm and may involve the useof many different chemical compositions for this purpose. However, in arepresentative and preferred embodiment, exemplary compositions whichmay be employed as the ink receiving layer 212 include but are notlimited to various resin compositions (e.g. Singapore Dammar Resin asdiscussed in U.S. Pat. Nos. 4,980,224 and 4,966,815), polyvinylpyrrolidone, polyvinyl alcohol, silica, and other compositions known inthe art for this purpose.

[0056] It is important to emphasize at this point that both the releaselayer 206 and ink receiving layer 212 are substantially colorless (e.g.transparent) so that the printed image applied to the ink receivinglayer 212 can be transferred (along with the release layer 206) to thefabric substrate and still be entirely visible through the layers 206,212 as discussed below. Likewise, the claimed invention shall also notbe limited to ink transfer sheets of any particular size, with thespecific size of the selected sheet depending on many factors includingthe printing system being used to deliver ink materials to the sheet.

[0057] As previously noted, the basic 3-layer ink transfer sheetstructure discussed above is conventional in design. However, thepresent invention involves a unique and important modification to thisproduct wherein an additional ingredient is added which ultimatelyenables clear, vivid, and more stable (e.g. waterfast) printed images tobe transferred to the desired fabric substrate. With continued referenceto FIG. 2, the ink transfer sheet 200 of the present inventionspecifically includes at least one quaternary ammonium salt as anadditional active ingredient on and/or within the ink receiving layer212 of the ink transfer sheet 200. The quaternary ammonium salt isschematically represented at reference number 214 in FIG. 2. The term“quaternary ammonium salt” as used herein shall be defined to involve amaterial which includes four separate groups (not necessarily the same)that are bonded to nitrogen in order to yield a positively-chargedquaternary ammonium ion (e.g. a cation). The positive charge of thiscation is balanced by a selected negatively-charged anion. A quaternaryammonium salt as defined herein will have the following basic structuralformula:

[0058] In the above formula, R₁, R₂, R₃, and R₄ may be selected from awide variety of organic groups including but not limited to aliphaticand/or aromatic groups which are substituted, non-substituted, branched,or non-branched as described in greater detail below. In accordance withthe definition provided above, R₁, R₂, R₃, and/or R₄ can also consist ofa hydrogen group (H), provided that at least one of R₁, R₂, R₃ and/or R₄is organic in character (e.g. carbon-containing). In addition, X⁻ willconsist of an anion selected from a wide variety of anions which willlikewise be discussed further below. For example, in a preferredembodiment, the following representative R₁, R₂, R₃, and R₄ groups maybe used as listed in the non-limiting Examples below:

EXAMPLE 1

[0059] R₁=—C_(n)H_(2n+1); —C_(n)H_(2n−1); —C_(n)H_(2n−2); —CH₂ (C₆H₅);or H

[0060] (wherein n is an integer ≧10 and ≦22).

[0061] R₂=R₃=R₄=—C_(n)H_(2m+1); —C_(n)H_(2m−1); —C_(n)H_(2m−2)

[0062] (wherein m is an integer ≦8).

EXAMPLE 2

[0063] R₁=R₂=—C_(n)H_(2n+1); —C_(n)H_(2n−1); —C_(n)H_(2n−2); —CH₂(C₆H₅);or H

[0064] (wherein n is an integer ≧10 and ≦22).

[0065] R₃=R₄=—C_(n)H_(2m+1); —C_(n)H_(2m−1); —C_(n)H_(2m−2)

[0066] (wherein m is an integer ≦8).

EXAMPLE 3

[0067] R₁=R₂=R₃=R₄=—C_(n)H_(2m+1); —C_(n)H_(2m−1); —C_(n)H_(2m−2)

[0068] (wherein m is an integer ≦8).

[0069] Once again, it should be noted that hydrogen (H), as well as awide variety of organic constituents/groups (e.g. both alkyl, aryl,substituted alkyl, and substituted aryl) may be used in the presentinvention as R₁, R₂, R₃, and R₄ (provided that at least one of thesegroups is organic in character). Thus, the claimed process and productshall not be limited to any of the specific materials listed above, andinstead shall cover the use of a quaternary ammonium salt as previouslydefined in its broadest sense. It is also contemplated that polymericquaternary ammonium salt compositions may likewise be used.

[0070] In addition, X⁻ shall involve an anion (counterion) which may beselected from a wide variety of different groups including but notlimited to the following alternatives: Cl^(−, Br) ⁻, I⁻, PO₄ ⁻³, SO₄ ⁻²,CH₃SO₃ ^(−, C) ₂H₅SO₃ ^(−, CH) ₃COO⁻ or C₂H₅COO⁻. Once again, theclaimed invention shall not be restricted to the anions listed above,and it is contemplated that a wide variety of other suitable anions mayalso be used.

[0071] Salt solutions containing quaternary ammonium salts as describedherein may be prepared by dissolving a given solid salt in an aqueoussolution consisting primarily or entirely of water. Dissolution in thismanner produces free quaternary ammonium ions (R₁, R₂, R₃, R₄N⁺) whichare available for reaction in accordance with the present invention asdiscussed below. Representative salts suitable for use in the claimedproduct and process (e.g. on or within the ink receiving layer 212 ofthe ink transfer sheet 200) include but are not limited to tricaprylylmethyl ammonium chloride, ditallow dimethyl ammonium chloride,tetraoctyl ammonium bromide, and tridodecyl ammonium chloride. Theabove-listed quaternary ammonium salts and other quaternary ammoniumsalts suitable for use herein are commercially available from a widevariety of sources including but not limited to Aldrich Chemical Companyof Milwaukee, Wis. (USA), Fluka of Switzerland, Akzo of Dobbs Ferry,N.Y. (USA), and Polysciences of Warrington, Pa. (USA).

[0072] As previously stated, the quaternary ammonium salt solutions usedin producing the ink transfer sheet 200 are typically prepared bydissolving solid quaternary ammonium salts in water. In a preferredembodiment, quaternary ammonium salt concentration levels of theresulting solutions should be about 0.5-15% by weight. Solutions havingthis salt concentration level are manufactured in accordance withconventional, known chemical practices. For example, to prepare a 10% byweight solution of tricaprylyl methyl ammonium chloride which is apreferred quaternary ammonium salt composition in this case, 10 g ofsalt would be added to 40 g of isopropanol and 50 g of water. Regardingthe use of isopropanol, this material is preferably added to thesolutions of quaternary ammonium salts which are employed to produce theclaimed ink transfer sheets 200. This material functions as a solventand, to achieve optimum results, solutions of quaternary ammonium saltsprepared in accordance with the invention will include about 30-50% byweight isopropanol. However, the use of isopropanol may not be requiredin all cases, depending on the type of quaternary ammonium salt beingused. In this regard, the addition of isopropanol in any given situationmay be determined in accordance with routine preliminary tests on thespecific solutions of interest. In addition, the quaternary ammoniumsalt solutions used in the present process may also contain an optionalpenetrant known in the art which decreases drying time if needed.Exemplary and preferred penetrants include but are not limited to butylcarbitol, butyl cellusolve, pentanol, and butanol. If used, it ispreferred that the penetrant be added to the quaternary ammonium saltsolutions so that the solutions comprise about 0.1-10% by weightpenetrant.

[0073] With reference to FIG. 2, the selected quaternary ammonium saltsolution may be applied (delivered) to the upper surface 216 of the inkreceiving layer 212 on the ink transfer sheet 200 in many differentways, with the present invention not being limited to any particularapplication method. For example, a supply 220 of a selected quaternaryammonium salt solution of the type described above may be retainedwithin a containment tank 222 that is operatively connected via tubularconduit 224 (having in-line pump 226 therein of a conventional fluiddisplacement variety) to a standard mist-type spraying apparatus 230.The supply 220 of the quaternary ammonium salt solution may then bedelivered to the upper surface 216 of the ink receiving layer 212 in theform of a uniformly-distributed mist 232 schematically shown in FIG. 2.The selected quaternary ammonium salt solution may also be applied usingconventional “draw down” techniques, as well as a standard roller orimmersion apparatus. In addition, the quaternary ammonium salt solutionmay even be retained within one of the chambers in a multi-chamberthermal inkjet cartridge unit and thereafter delivered prior to orsimultaneously with the delivery of the selected ink composition to an“untreated” ink transfer sheet structure containing all of the layersillustrated in FIG. 2.

[0074] As indicated above, the ink receiving layer 212 of the completedink transfer sheet 200 will comprise (e.g. contain) a selectedquaternary ammonium salt of the type previously described. The term“comprise” as used herein shall involve a situation in which thequaternary ammonium salt resides in a discrete salt layer 234 (FIG. 2)on the upper surface 216 of the ink receiving layer 212 or is partially(or entirely) impregnated within the ink receiving layer 212. Both ofthese embodiments shall be deemed equivalent to each other in functionand character. With reference to FIG. 3, an ink transfer sheet 200 ofthe same type as the sheet 200 illustrated in FIG. 2 is shown having thequaternary ammonium salt (designated at reference number 236 in FIG. 3)partially on the upper surface 216 of the ink receiving layer 212 andpartially imbedded (e.g. impregnated) within the ink receiving layer212. A number of different factors as determined by preliminary pilotexperimentation will determine the extent of impregnation that will takeplace regarding the quaternary ammonium salt compositions. These factorsinclude but are not limited to (1) the type and amount of quaternaryammonium salt solution being applied; (2) the chemical character (e.g.absorptivity and porosity) of the ink receiving layer 212; and (3) theapplication method used to apply the quaternary ammonium salt solution.It is also contemplated that the ink receiving layer 212 may bemanufactured so that the chemical composition used to produce the layer212 is initially combined (e.g. mixed/blended) with the selectedquaternary ammonium salt solution prior to application of the inkreceiving layer 212 to the release layer 206. In this manner, the inkreceiving layer 212 will contain the desired quaternary ammonium saltcomposition therein when it is initially formed on the release layer206. However, it is nonetheless preferred that the quaternary ammoniumsalt be applied directly to the upper surface 216 of the ink receivinglayer 212 so that all of the upper surface 216 is completelycoated/covered.

[0075] To achieve optimum results it is desired and preferred that theselected quaternary ammonium salt be applied to the ink transfer sheet200 in an amount sufficient to achieve a dried quaternary ammonium saltcontent of about 2-10 g of total (combined) quaternary ammonium salt persquare meter (m²) of the ink transfer sheet 200. This is typicallyaccomplished by applying about 1.0-6.0 ml of the desired quaternaryammonium salt solution having a concentration within the preferred rangelisted above (e.g. about 0.5-15% by weight quaternary ammonium salt) tothe ink transfer sheet 200 per m² thereof. However, the exact amount ofquaternary ammonium salt to be used in a given situation to achieveideal results may be varied as needed and determined by preliminarypilot studies involving the specific ink materials (and anionic coloringagents) of interest. As discussed further below, the quaternary ammoniumsalt used in the claimed process and product provides importantfunctional benefits. Specifically, the anionic coloring agent in the inkcomposition binds to the quaternary ammonium salt on the ink transfersheet 200 in order to “fix” the ink composition to the transfer sheet200 and ultimately produce a more vivid and stable (e.g. waterfast)printed image on the fabric substrate.

D. The Printing Process

[0076] A representative process for generating stable printed images ona fabric substrate using the materials discussed above will now bediscussed. While many different inkjet and other printing systems may beemployed to deliver the desired ink composition onto the ink transfersheet 200, the present invention shall be primarily discussed inconnection with the use of thermal inkjet technology. Again, the desiredimage may either be monochrome (e.g. black) or multi-colored dependingon the desired character of the final image and the equipment beingemployed.

[0077] With reference to FIG. 4. a thermal inkjet printing unit 300 isprovided. Many different systems may be used in connection with theprinting unit including printers manufactured by the Hewlett-PackardCompany of Palo Alto, Calif. (USA) under the product designationsDESKJET 400C, 500C, 540C, 560C, 660C, 682C, 693C, 820C, 850C, 870C,1200C, and 1600C. An ink cartridge unit (e.g. cartridge unit 10illustrated in FIG. 1) is provided within the printing unit 300 which issupplied with the selected ink composition 100. As noted above, the inkcomposition contains at least one anionic coloring agent and an inkvehicle. Next, an ink transfer sheet 200 of the type previouslydiscussed is provided and inserted (e.g. placed) into the printing unit300 with the ink receiving layer 212 facing upwardly toward the inkcartridge 10. With continued reference to FIG. 4, the printing unit 300is electrically connected to an image generating apparatus 302 which mayinvolve many different systems selected from the group consisting of apersonal computer (e.g. of the type manufactured by the Hewlett-PackardCompany of Palo Alto Calif. (USA) under the trademark “PAVILION®”), ascanner unit (of the variety sold by the Hewlett-Packard Company of PaloAlto Calif. (USA) under the trademark “SCANJET®”) or both. In thisregard, the claimed process shall not be restricted to the use of anyparticular image generation device or protocol.

[0078] Next, the image generating apparatus 302 and the printing unit300 are cooperatively activated in order to deliver a desired printedimage onto the ink transfer sheet 200. Both the image generatingapparatus 302 and the printing unit 300 are used to initiate theoperation of the ink cartridge 10. The printing process-is initiated byactivation of the ink expulsion means 68 of the ink cartridge 10. Inparticular, the term “activation” shall again involve a process in whichthe ink expulsion means 68 of ink cartridge 10 is directed by theprinting unit 300 to deliver ink from the chamber 33 to the ink transfersheet 200. This is specifically accomplished in the present embodimentby selectively energizing the thin film resistors 58 on the plate member56 of the cartridge 10 (FIG. 1). As a result, ink positioned at theopening 60 in the plate member 56 is thermally excited and expelledoutwardly through the ink ejection orifice 66 in the orifice plate 62onto the ink transfer sheet 200. In this manner, the cartridge 10 may beused to deliver a printed image 304 onto the ink transfer sheet 200(FIG. 4) using the ink composition 100.

[0079] With continued reference to FIG. 4, the ink transfer sheet 200 isnow ready to be used in the production of a printed fabric product. Thetransfer sheet 200 in FIG. 4 is schematically illustrated and, for thesake of clarity, only illustrates the backing layer 202, the releaselayer 206, the ink receiving layer 212, and the printed image 304. Thequaternary ammonium salt 214 previously shown in FIGS. 2 and 3 is notillustrated in FIG. 4 since, at this point, it has formed an ink complexassociated with the printed image 304. However, at the present time, itis important to emphasize the important functional capabilities of thequaternary ammonium salt and how it interacts with the ink composition100 to yield a vivid and stable printed image 304. Prior to activationof the printing unit 300 as discussed above, the treated ink transfersheet 200 will have quaternary ammonium salts thereon or impregnatedtherein. When liquid ink materials (e.g. the ink composition 100) aresubsequently applied to the ink transfer sheet 200 (e.g. using thermalinkjet technology), they cause re-solvation of the salts, therebyproducing free quaternary ammonium ions (e.g. R₁, R₂, R₃, R₄N⁺). Theseions are then able to interact with reactive functional groups (e.g.—SO₃ ⁻ and/or —COO⁻ groups) on the anionic coloring agent in the inkcomposition 100 so that waterfastness problems are controlled and imagestability is achieved. Specifically, an insoluble coloring agent“complex” is formed on the ink transfer sheet 200 from the interactionwhich takes place between the anionic coloring agent in the inkcomposition 100 and the quaternary ammonium ions. This interaction iscaused by the attraction between oppositely-charged species, namely, thepositively-charged quaternary ammonium ions and the negatively-chargedanionic coloring agents. As a result, a chemical “complex” is producedwhich is prevented from spreading, wicking, migrating, or otherwisebleeding beyond the initial ink droplet boundaries on the ink transfersheet 200. This situation occurs because the rate of diffusionassociated with the dye/colorant complex is much slower than the rate ofdiffusion involving uncomplexed coloring agents. As a result, a vividand crisp printed image 304 is generated which is waterfast, does notcolor-bleed (e.g. in the case of multi-colored images), and ischaracterized by a consistent degree of quality even after multiplemachine washings of the final printed fabric substrate as discussedbelow.

[0080] The complexation reaction described above occurs in a highlyeffective and unexpectedly efficient manner. While not completelyunderstood, the binding/complexation reaction between quaternaryammonium ions and reactive groups (e.g. —COO⁻ and/or —SO₃ ⁻ groups) onthe coloring agent molecules is schematically illustrated below. In thefollowing example, N ⁺represents a quaternary ammonium ion of the typedescribed herein which is combined with a dye having —COO⁻ and —SO₃ ⁻groups:

[0081] Next, the ink transfer sheet 200 with the printed image 304thereon is removed from the printing unit 300. As illustratedschematically in FIG. 4, it is important to note that the printed image304 is applied to the ink transfer sheet 200 in a “reverse”configuration so that it will be properly oriented on the final fabricsubstrate. A suitable fabric substrate 306 is then chosen. Manydifferent items and materials may be used in connection with the fabricsubstrate 306 which shall not be limited to any particular textilematerials/compositions. For example, the fabric substrate 306 mayactually consist of a T-shirt or other conventional clothing item madefrom 100% cotton, 50-50 cotton/polyester blends, as well as othermaterials (e.g. rayon, wool, nylon, silk, and the like). To transfer theprinted image 304 from the ink transfer sheet 200 to the upper surface310 of the fabric substrate 306, the substrate 306 is first placed on aflat, hard support surface 312 (e.g. a table or other rigid item) andsmoothed out so that no wrinkles are present. This may be accomplishedby initially ironing or pressing the substrate 306 using a conventionaliron/clothing press system which is well known in the art. Thereafter,the ink transfer sheet 200 with the printed image 304 thereon ispositioned directly on the fabric substrate 306 so that the inkreceiving layer 212 (and printed image 304) is in direct physicalcontact with the upper surface 310 of the fabric substrate 306.

[0082] Heat is then applied to the bottom surface 314 of the backinglayer 202 using a conventional pressing/ironing apparatus 316 or otherheated platen unit known in the art for thermal fabric transferpurposes. In a representative and preferred embodiment suitable forin-home use by consumers, a standard household iron may be employed forthis purpose. During this step, a sufficient amount of heat is appliedto the ink transfer sheet 200 to cause the release layer 206 and inkreceiving layer 212 of the transfer sheet 200 to adhere to the uppersurface 310 of the fabric substrate 306. In particular, the amount ofheat applied to the ink transfer sheet 200 should be sufficient to (1)cause the low melting point polymeric materials used to form the releaselayer 206 of the ink transfer sheet 200 to soften and “flow” (along withthe ink receiving layer 212 and printed image 304) onto the uppersurface 310 of the fabric substrate 306; and (2) cause the release layer206 to soften sufficiently to enable the detachment thereof from thebacking layer 202 in a rapid and complete manner as discussed below. Ina preferred embodiment using the materials and compositions recitedabove, these goals are accomplished by heating the ink transfer sheet200 to a temperature of about 150-200° C. for about 0.3-3.0 minutesusing the ironing/pressing apparatus 316. However, it many be necessaryto vary these parameters depending on a wide variety of factorsincluding the chemical content of the ink transfer sheet being employedand the type of fabric substrate being used as determined by preliminarytesting. Likewise, to ensure complete transfer of the printed image 304to the fabric substrate 306 during the application of heat as notedabove, it is preferred that pressure be applied to the ink transfersheet 200 positioned on the substrate 306 in an amount sufficient tofacilitate complete contact between the transfer sheet 200 and thesubstrate 306. In a representative embodiment, this pressure wouldtypically involve about 0.05-2.0 lbs/in² of the transfer sheet 200,although the exact pressure to be used in a given situation may bedetermined in accordance with preliminary routine testing.

[0083] After this step is completed and the ink transfer sheet 200 hasbeen sufficiently heated, the backing layer 202 of the transfer sheet200 is physically grasped and removed (e.g. peeled) from the otherlayers (the release layer 206 and the ink receiving layer 212 having theprinted image 304 thereon) as illustrated schematically in FIG. 4. As aresult, the backing layer 202 is separated from both the release layer206 and attached ink receiving layer 212 which remain adhered to theupper surface 310 of the fabric substrate 306. This adhesion processbasically occurs because the release layer 206 softens and flows aroundthe individual fibers/microscopic surface irregularities of the fabricsubstrate 306 in order to mechanically bond to the surface of thesubstrate 306. The ink receiving layer 212 and printed image 304 thereonare then trapped against the substrate 306. In this manner, the printedimage 304 is effectively transferred to the upper surface 310 of thefabric substrate 306. It is important to note that the printed image 304(which is now oriented in its proper position) is readily visible on thefabric substrate 306 since both the release layer 206 and the inkreceiving layer 212 are substantially colorless (e.g. transparent).

[0084] The resulting final printed product 320 is shown in FIG. 4. Theprinted image 304 on the product 320 is clear, vivid, and highlywaterfast. The printed image 304 specifically resists fading, bleeding,and visual distortion after multiple machine washings compared withtransfer processes that do not employ the quaternary ammonium salt-basedsystem discussed above. Accordingly, the claimed invention represents anadvance in the art of thermal fabric printing and provides many benefitsincluding but not limited to (1) the rapid printing of clear, vivid, anddistinct images with a minimal amount of equipment and process steps;(2) enhanced image waterfastness and fade-resistance; (3) a minimallevel of complexity and required equipment which facilitates at-home useby consumers; (4) the ability to use thermal inkjet technology togenerate high-resolution multi-color images which are characterized byimproved stability levels; and (5) the ability to accomplish these goalsusing low-cost materials and equipment.

[0085] Having herein set forth preferred embodiments of the presentinvention, it is anticipated that suitable modifications may be madethereto by individuals skilled in the art which nonetheless remainwithin the scope of the invention. For example, the invention shall notbe limited to any particular ink compositions, printing technologies,heating equipment, and material layers used to manufacture the inktransfer sheets. In this regard, the present invention shall only beconstrued in accordance with the following claims:

The invention that is claimed is:
 1. A method for applying a stableprinted image onto a fabric substrate comprising the steps of: providinga multi-layer ink transfer sheet comprising a backing layer, adetachable release layer positioned on said backing layer, and an inkreceiving layer positioned on said release layer, said ink receivinglayer comprising at least one quaternary ammonium salt; providing an inkcomposition comprising at least one anionic coloring agent and an inkvehicle; delivering said ink composition onto said ink receiving layerof said ink transfer sheet in order to form a printed image on said inktransfer sheet, said anionic coloring agent in said ink compositionbinding to said quaternary ammonium salt in order to fix said coloringagent to said ink transfer sheet; placing said ink transfer sheet onsaid fabric substrate so that said ink receiving layer of said inktransfer sheet is in contact with said fabric substrate; applying heatto said ink transfer sheet while said ink transfer sheet is positionedon said fabric substrate in an amount sufficient to cause said releaselayer and said ink receiving layer thereon to adhere to said fabricsubstrate; and removing said backing layer from said ink transfer sheetin order to-separate said release layer from said backing layer, saidrelease layer and said ink receiving layer remaining adhered to saidfabric substrate so that said printed image is transferred thereto. 2.The method of claim 1 wherein said quaternary ammonium salt is selectedfrom the group consisting of tricaprylyl methyl ammonium chloride,ditallow dimethyl ammonium chloride, tetraoctyl ammonium bromide, andtridodecyl ammonium chloride.
 3. The method of claim 1 wherein saidapplying of said heat to said ink transfer sheet comprises heating saidink transfer sheet to a temperature of about 150-200° C. while said inktransfer sheet is positioned on said fabric substrate.
 4. The method ofclaim 1 wherein said ink transfer sheet comprises about 2-10 g of saidquaternary ammonium salt per m² of said ink transfer sheet.
 5. Themethod of claim 1 further comprising the step of applying pressure tosaid ink transfer sheet during said applying of said heat thereto in anamount sufficient to ensure complete contact between said ink transfersheet and said fabric substrate.
 6. The method of claim 5 wherein saidpressure applied to said ink transfer sheet is about 0.05-2.0 lbs/in² ofsaid transfer sheet.
 7. A method for applying a stable printed imageonto a fabric substrate comprising the steps of: providing a multi-layerink transfer sheet comprising a backing layer, a detachable releaselayer positioned on said backing layer, and an ink receiving layerpositioned on said release layer, said ink receiving layer comprising atleast one quaternary ammonium salt; providing a thermal inkjet printingapparatus comprising at least one ink cartridge therein, said inkcartridge comprising a housing and a printhead, said printheadcomprising ink expulsion means for delivering ink materials from saidink cartridge, said ink cartridge further comprising a supply of atleast one ink composition within said housing, said supply of said inkcomposition being in fluid communication with said ink expulsion meansof said printhead, said ink composition comprising at least one anioniccoloring agent and an ink vehicle; placing said ink transfer sheetwithin said thermal inkjet printing apparatus; activating said inkexpulsion means of said printhead in order to deliver said inkcomposition from said ink cartridge onto said ink receiving layer ofsaid ink transfer sheet so that a printed image is formed on said inktransfer sheet, said anionic coloring agent in said ink compositionbinding to said quaternary ammonium salt in order to fix said coloringagent to said ink transfer sheet; placing said ink transfer sheet onsaid fabric substrate so that said ink receiving layer of said inktransfer sheet is in contact with said fabric substrate; applying heatto said ink transfer sheet while said ink transfer sheet is positionedon said fabric substrate in an amount sufficient to cause said releaselayer and said ink receiving layer thereon to adhere to said fabricsubstrate; and removing said backing layer from said ink transfer sheetin order to separate said release layer from said backing layer, saidrelease layer and said ink receiving layer remaining adhered to saidfabric substrate so that said printed image is transferred thereto. 8.The method of claim 7 wherein said quaternary ammonium salt is selectedfrom the group consisting of tricaprylyl methyl ammonium chloride,ditallow dimethyl ammonium chloride, tetraoctyl ammonium bromide, andtridodecyl ammonium chloride.
 9. The method of claim 7 wherein saidapplying of said heat to said ink transfer sheet comprises heating saidink transfer sheet to a temperature of about 150-200° C. while said inktransfer sheet is positioned on said fabric substrate.
 10. The method ofclaim 7 wherein said ink transfer sheet comprises about 2-10 g of saidquaternary ammonium salt per m² of said ink transfer sheet.
 11. A methodfor applying a stable printed image onto a fabric substrate comprisingthe steps of: providing a multi-layer ink transfer sheet comprising abacking layer, a detachable release layer positioned on said backinglayer, and an ink receiving layer positioned on said release layer, saidink receiving layer comprising at least one quaternary ammonium saltselected from the group consisting of tricaprylyl methyl ammoniumchloride, ditallow dimethyl ammonium chloride, tetraoctyl ammoniumbromide, and tridodecyl ammonium chloride, said ink transfer sheetcomprising about 2-10 g of said quaternary ammonium salt per m of saidink transfer sheet; providing a thermal inkjet printing apparatuscomprising at least one ink cartridge therein, said ink cartridgecomprising a housing and a printhead, said printhead comprising inkexpulsion means for delivering ink materials from said ink cartridge,said ink cartridge further comprising a supply of at least one inkcomposition within said housing, said supply of said ink compositionbeing in fluid communication with said ink expulsion means of saidprinthead, said ink composition comprising at least one anionic coloringagent and an ink vehicle; placing said ink transfer sheet within saidthermal inkjet printing apparatus; activating said ink expulsion meansof said printhead in order to deliver said ink composition from said inkcartridge onto said ink receiving layer of said ink transfer sheet sothat a printed image is formed on said ink transfer sheet, said anioniccoloring agent in said ink composition binding to said quaternaryammonium salt in order to fix said coloring agent to said ink transfersheet; placing said ink transfer sheet on said fabric substrate so thatsaid ink receiving layer of said ink transfer sheet is in contact withsaid fabric substrate; heating said ink transfer sheet to a temperatureof about 150-200° C. while said ink transfer sheet is positioned on saidfabric substrate in order to cause said release layer and said inkreceiving layer thereon to adhere to said fabric substrate; and removingsaid backing layer from said ink transfer sheet in order to separatesaid release layer from said backing layer, said release layer and saidink receiving layer remaining adhered to said fabric substrate so thatsaid printed image is transferred thereto.
 12. A multi-layer inktransfer sheet for receiving ink compositions thereon and subsequentlytransferring said ink compositions to a fabric substrate comprising: abacking layer; a detachable release layer positioned on said backinglayer; and an ink receiving layer positioned on said detachable releaselayer, said ink receiving layer comprising at least one quaternaryammonium salt, said quaternary ammonium salt binding to any anioniccoloring agents within said ink compositions applied to said inktransfer sheet in order to produce a stable printed image.
 13. The inktransfer sheet of claim 12 wherein said quaternary ammonium salt isselected from the group consisting of tricaprylyl methyl ammoniumchloride, ditallow dimethyl ammonium chloride, tetraoctyl ammoniumbromide, and tridodecyl ammonium chloride.
 14. The ink transfer sheet ofclaim 12 wherein said ink transfer sheet comprises about 2-10 g of saidquaternary ammonium salt per m² of said ink transfer sheet.
 15. Amulti-layer ink transfer sheet for receiving ink compositions thereonand subsequently transferring said ink compositions to a fabricsubstrate comprising: a backing layer; a detachable release layerpositioned on said backing layer; and an ink receiving layer positionedon said detachable release layer, said ink receiving layer comprising atleast one quaternary ammonium salt selected from the group consisting oftricaprylyl methyl ammonium chloride, ditallow dimethyl ammoniumchloride, tetraoctyl ammonium bromide, and tridodecyl ammonium chloride,said ink transfer sheet comprising about 2-10 g of said quaternaryammonium salt per m² of said ink transfer sheet, said quaternaryammonium salt binding to any anionic coloring agents within said inkcompositions applied to said ink transfer sheet in order to produce astable printed image.
 16. A method for producing a multi-layer inktransfer sheet for receiving ink compositions thereon and subsequentlytransferring said ink compositions to a fabric substrate comprising:providing a transfer sheet structure comprising a backing layer, adetachable release layer positioned on said backing layer, and an inkreceiving layer positioned on said release layer, said ink receivinglayer comprising an upper surface; and delivering at least onequaternary ammonium salt onto said upper surface of said ink receivinglayer of said transfer sheet structure to produce a completed inktransfer sheet, said quaternary ammonium salt binding to any anioniccoloring agents within said ink compositions applied to said inktransfer sheet in order to produce a stable printed image.
 17. Themethod of claim 16 wherein said quaternary ammonium salt is selectedfrom the group consisting of tricaprylyl methyl ammonium chloride,ditallow dimethyl ammonium chloride, tetraoctyl ammonium bromide, andtridodecyl ammonium chloride.
 18. The method of claim 16 wherein saidink transfer sheet comprises about 2-10 g of said quaternary ammoniumsalt per m² of said ink transfer sheet.
 19. A method for producing amulti-layer ink transfer sheet for receiving ink compositions thereonand subsequently transferring said ink compositions to a fabricsubstrate comprising: providing a transfer sheet structure comprising abacking layer, a detachable release layer positioned on said backinglayer and an ink receiving layer positioned on said release layer, saidink receiving layer comprising an upper surface; and delivering at leastone quaternary ammonium salt selected from the group consisting oftricaprylyl methyl ammonium chloride, ditallow dimethyl ammoniumchloride, tetraoctyl ammonium bromide, and tridodecyl ammonium chlorideonto said upper surface of said ink receiving layer of said transfersheet structure to produce a completed ink transfer sheet, said inktransfer sheet comprising about 2-10 g of said quaternary ammonium saltper m² of said ink transfer sheet, said quaternary ammonium salt bindingto any anionic coloring agents within said ink compositions applied tosaid ink transfer sheet in order to produce a stable printed image.